Unitary gas burner

ABSTRACT

A gas burner and a gas burner assembly for an appliance are provided. The gas burner assembly includes a unitary gas burner comprising a body portion, a cap portion, and a gas conduit portion. A plurality of burner ports is defined in the sidewall of the body portion of the unitary gas burner. A gas burner is also provided. The gas burner comprises a body portion, a cap portion, and a gas conduit portion that are segments of a single piece forming the gas burner.

FIELD OF THE INVENTION

The subject matter of the present disclosure relates generally to a gas burner for the cooktop of an appliance.

BACKGROUND OF THE INVENTION

Gas burners commonly are used on the cooktops of household gas cooking appliances, including, e.g., range ovens and cooktops built into cabinetry. Because of, e.g., limitations in traditional manufacturing processes, such burners typically are assembled from several separate pieces, such as a burner body, a cap, and a gas conduit. For consistent burner performance, the tolerances and clearance fits for these pieces generally are small, e.g., gaps in the interface between the burner body and the cap, which is placed on top of the burner body, often must be controlled to less than 0.008 inches. These tolerances are difficult to maintain with typical manufacturing processes, such as, e.g., forging and casting.

Additionally, gas burners commonly are exposed to extremely high temperatures, e.g., between 700° F. and 1100° F., and over time, exposure to such high temperatures can cause the gas burner components to warp. Some materials, such as, e.g., die cast aluminums, can permanently expand with age and exposure to high temperatures. The expansion and/or deformation of burner components can interfere with the performance of the gas burner by altering how the burner components fit together, specifically with respect to the mating of dissimilar materials.

Accordingly, a gas burner with one or more features for eliminating tolerance and clearance fit issues would be useful. A gas burner having with one or more features for eliminating the use of dissimilar materials would be beneficial.

BRIEF DESCRIPTION OF THE INVENTION

The present invention provides a gas burner and a gas burner assembly for an appliance. The gas burner assembly includes a unitary gas burner comprising a body portion, a cap portion, and a gas conduit portion. A plurality of burner ports is defined in the sidewall of the body portion of the unitary gas burner. A gas burner is also provided. The gas burner comprises a body portion, a cap portion, and a gas conduit portion that are segments of a single piece forming the gas burner. Additional aspects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention.

In one exemplary embodiment, a gas burner assembly for a cooktop of an appliance is provided. The gas burner assembly includes a unitary gas burner comprising a body portion having a sidewall and extending between a base section and a top section. The body portion also has an interior surface defining a fuel chamber. The gas burner assembly further includes a cap portion defined at the top section of the sidewall; a plurality of burner ports defined along the sidewall of the body portion; and a gas conduit portion defining a gas inlet and a gas outlet. The gas outlet is positioned adjacent the fuel chamber of the body portion. The gas burner assembly also includes an igniter and a gas supply conduit for supplying gas to the unitary gas burner.

In another exemplary embodiment, a gas burner for a cooktop of an appliance is provided. The gas burner includes a body portion having a sidewall and extending between a base section and a top section. The body portion also has an interior surface defining a fuel chamber. The gas burner further includes a cap portion defined at the top section of the sidewall; a plurality of burner ports defined along the sidewall of the body portion; and a gas conduit portion defining a gas inlet and a gas outlet. The gas outlet is positioned adjacent the fuel chamber of the body portion. The body portion, cap portion, and gas conduit portion are segments of a single piece forming the gas burner.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 provides an exemplary embodiment of a cooktop appliance 100 according to the present subject matter.

FIG. 2 provides an exploded view of an exemplary gas burner assembly according to the present subject matter.

FIG. 3 provides a cross-section view of an exemplary gas burner of the gas burner assembly of FIG. 2.

Use of identical reference numerals in different figures denotes the same or similar components or features.

DETAILED DESCRIPTION OF THE INVENTION

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 illustrates an exemplary embodiment of a cooktop appliance 100 as may be employed with the present subject matter. Cooktop appliance 100 includes a top panel 104. By way of example, top panel 104 may be constructed of glass, ceramics, enameled steel, and combinations thereof. Top panel 104 may be part of a range or other appliance, or panel 104 may be a stand-alone appliance.

For cooktop appliance 100, a utensil holding food and/or cooking liquids (e.g., oil, water, etc.) may be placed onto grates 116 at a location of any of a plurality of burner assemblies 110. As shown in FIG. 1, burner assemblies 110 can be configured in various sizes so as, e.g., to provide for the receipt of cooking utensils (i.e., pots, pans, etc.) of various sizes and configurations and to provide different heat inputs for such cooking utensils. Grates 116 are supported on a top surface 118 of top panel 104.

Burner assemblies 110 provide thermal energy to cooking utensils on grates 116. In particular, burner assemblies 110 extend through top panel 104 below grates 116. Burner assemblies 110 are also mounted to top panel 104. Burner assemblies 110 provide for combustion of a gaseous fuel to provide heat energy for cooking.

A user interface panel 112 is located within convenient reach of a user of the cooktop appliance 100. For this exemplary embodiment, panel 112 includes knobs 114 that are each associated with one of burner assemblies 110. Knobs 114 allow the user to activate each burner assembly 110 and determine the amount of heat input provided by each burner assembly 110 to a cooking utensil located thereon. Panel 112 may also be provided with one or more graphical display devices that deliver certain information to the user such as, e.g., whether a particular burner assembly is activated and/or the level at which the burner assembly is set.

Although shown with knobs 114, it should be understood that knobs 114 and the configuration of cooktop appliance 100 shown in FIG. 1 are provided by way of example only. More specifically, user interface 112 may include various input components, such as one or more of a variety of touch-type controls, electrical, mechanical, or electro-mechanical input devices including rotary dials, push buttons, and touch pads. Additionally, the user interface 112 may include other display components, such as a digital or analog display device designed to provide operational feedback to a user.

Cooktop appliance 100 shown in FIG. 1 illustrates an exemplary embodiment of the present subject matter. Thus, although described in the context of cooktop appliance 100, the present subject matter may be used in cooktop appliances having other configurations, e.g., a cooktop appliance with one, two, or more additional burner assemblies. Similarly, the present subject matter may be used in cooktop appliances that are part of an oven such as, e.g., range appliances.

FIG. 2 illustrates an exemplary embodiment of a gas burner assembly 110 as may be used with cooktop appliance 100. As shown, gas burner assembly 110 includes a burner 120, an igniter 160, a bracket 162, and a gas supply conduit 168. Igniter 160 is in electrical communication with an electrical source (not shown, e.g., a power supply of one or more electrical features of cooktop 100) such that igniter 160 selectively creates, carries, or directs a voltage differential that can create an electrical arc that ignites gaseous fuel within burner assembly 110. Further, bracket 162 has a top surface 164 that faces a bottom surface 119 of top panel 104 and is positioned adjacent bottom surface 119; bracket 162 may be attached or mounted to top panel 104 with one or more appropriate fasteners. Bracket 162 also includes a gas line support 166 disposed below top surface 164 of bracket 162 along axial direction A. Gas line support 166 may receive and support gas supply conduit 168. As is understood by those skilled in the art, such tubing can direct a flow of gaseous fuel (e.g., propane or natural gas) from a fuel source (not shown) to gas burner assembly 110.

The configuration of gas burner assembly 110 is provided by way of example only; other types and configurations of igniters 160, brackets 162, and gas supply conduits 168, as well as different or additional components, may also be used.

FIG. 3 is a cross-section view of gas burner 120 as may be used in exemplary burner assembly 110. As may be seen in FIG. 3, gas burner 120 includes a body portion 122 integrally formed with a gas conduit portion 130 and a cap portion 138. Thus, gas burner 120 is a unitary gas burner such that, e.g., body portion 122, gas conduit portion 130, and cap portion 138 are of a unitary construction, i.e., constructed of a single continuous piece of material. For example, body portion 122, gas conduit portion 130, and cap portion 138 may be segments of a single, continuous piece of a metal or other appropriate material forming gas burner 120, as discussed in greater detail below.

Body portion 122 is a frustum or frusto-conical shaped portion of burner 120. Body portion 122 includes a sidewall 124 and extending between a base section 126 and a top section 128. That is, sidewall 124 may gradually decrease in circumference from base section 126 to top section 128. Base section 126 can, e.g., be attached or mounted to top panel 104 of cooktop 100 with one or more appropriate fasteners, or base section 126 may rest on top panel 104 of cooktop 100. As such, base section 126 may be an external support portion of body portion 122, supporting burner 120 on top panel 104 of cooktop 100. Body portion 122 may have other shapes, such as, e.g., a cylindrical shape, and configurations as well.

Sidewall 124 extends around a circumferential direction C of body portion 122. A gas conduit portion 130 projects along axial direction A and defines a gas inlet 132 and a gas outlet 134 for gas flow G. As used herein, “gas” or “gas flow” or “fuel” refers to a combustible gas or gaseous fuel mixture. Gas supply conduit 168 is in fluid communication with gas conduit portion 130 of unitary gas burner 120 to supply gas flow G from a fuel supply to burner 120, as previously described.

Further, sidewall 124 defines a plurality of burner ports 136 that, for this exemplary embodiment, are of differing diameters and are evenly spaced apart from each other along the circumferential direction C. As used herein, port refers to an aperture or opening from which a flame may be supported. As further described below, burner ports 136 may be particularly shaped for ease of fabrication or manufacture of unitary gas burner 120. Additionally, sidewall 124 may define an indented portion 146 for the receipt of igniter 160.

A cap portion 138 is received onto top section 128 of sidewall 124 of body portion 122. As shown in FIGS. 2 and 3, the circumference of cap portion 138 is greater than the circumference of top section 128 of sidewall 124, and cap portion 138 may be curved about the axial direction A. A fuel chamber 140 is positioned between cap portion 138 and body portion 122. More specifically, fuel chamber 140 is defined by an inner surface 142 of body portion 122 and cap portion 138. Through gas outlet 134 and fuel chamber 140, burner ports 136 are in fluid communication with gas flow G in gas conduit portion 130.

As further shown in FIG. 3, cap portion 138 includes an interior support element 144 that projects along axial direction A into fuel chamber 140 from cap portion 138. Interior support element 144 may be, e.g., conical or triangular in shape, although other shapes may also be used. Interior support element 144 provides support for additional layers of material added during the three-dimensional printing process, such as, e.g., cap portion 138.

As described, burner 120 may be fabricated as a unitary gas burner such that, e.g., burner 120 is formed of a single continuous piece of metal such as, e.g., a stainless steel or a metal alloy, or other suitable material. More particularly, unitary gas burner 120 may be manufactured or formed using an additive process, such as Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), Stereolithography (SLA), Digital Light Processing (DLP), Direct Metal Laser Sintering (DMLS), Laser Net Shape Manufacturing (LNSM), electron beam sintering, three-dimensional printing, and other known processes. An additive process fabricates plastic or metal components using three-dimensional information, for example a three-dimensional computer model, of the component. The three-dimensional information is converted into a plurality of slices, each slice defining a cross section of the component for a predetermined height of the slice. The component is then “built-up” slice by slice, or layer by layer, e.g., by fusing or polymerizing a metallic powder using laser energy or heat, until the component is finished. The component may be fabricated using any suitable additive manufacturing machine. For example, any suitable laser sintering machine, inkjet printer, or laserjet printer may be used.

Various components, facets, features, or portions of burner 120 may be shaped to facilitate building up each successive layer of burner 120 during the additive fabrication process without requiring temporary support elements that are needed only to support layers of burner 120 during fabrication or manufacture of burner 120. For example, burner ports 136 may be round or triangular in shape, or any other appropriate shape such that each layer is capable of supporting the next successive layer without requiring temporary support elements. That is, burner ports 136 are of a shape that gradually changes along the axial direction A to form a closed shape. Thus, burner ports 136 may be formed using an additive process without requiring removal of material, such as temporary support elements, after the additive process has been completed.

Similarly, in the exemplary embodiment illustrated in FIG. 3, inner surface 142 is curved such that fuel chamber 140 is generally toroid-shaped. More specifically, inner surface 142 is curved about the circumferential direction C such that inner surface 142 is curved in multiple planes. Inner surface 142 may have any other appropriate shape such that fuel chamber 140 is formed without requiring temporary support elements within chamber 140, i.e., each successive layer of body portion 122 and cap portion 138 is supported by the preceding layer to form burner 120 having fuel chamber 140 as illustrated. Further, in some embodiments, all downward facing surfaces may be curved or at an angle with respect the radial direction R to eliminate the use of temporary support elements that would require removal in post-processing clean up. For example, as shown in FIGS. 2 and 3, cap portion 138 is curved about the axial direction A. Other portions of burner 120 may be shaped and/or configured to readily facilitate the fabrication of burner 120 by an additive process as described.

By avoiding the use of temporary support elements that are needed only to support layers of burner 120 during fabrication, unitary gas burner 120 requires less material and less post-fabrication clean up time and expense, because no temporary support elements must be removed from burner ports 136 or fuel chamber 140. However, in some embodiments, support elements may be incorporated into the design of unitary gas burner 120, and such support elements may not be removed in post-processing clean up. In the exemplary embodiment of FIG. 3, interior support element 144 is incorporated into the design of burner 120 and provides support during the fabrication of burner 120, specifically with respect to the layers that form cap portion 138. In addition, other embodiments may include external features of burner 120 that require temporary support elements, which, in contrast to internal temporary support elements, may be easily removed during post-fabrication clean up because they are located externally. In this way, various configurations of burner 120 may be used that are suitable for fabrication or manufacture using an additive process as described.

Accordingly, unitary gas burner 120 may have fewer components and/or joints than known gas burners. Specifically, burner 120 may require fewer components because burner 120 may be a single piece of continuous metal or other material, e.g., rather than multiple pieces of one or more materials joined or connected together. Thus, because burner 120 is constructed as one continuous piece, tolerance and clearance fit issues, e.g., between the burner body and the burner cap, can be eliminated. Also, because burner 120 is constructed as one continuous piece of a single material, thermal expansion issues resulting from the use of different materials can be eliminated or avoided. As a result, burner 120 may provide an improved gas burner life cycle, e.g., by retaining the characteristics and pattern of gas flow G over time.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. 

What is claimed is:
 1. A gas burner assembly for a cooktop of an appliance, comprising: a unitary gas burner comprising a body portion having a sidewall and extending between a base section and a top section, the body portion having an interior surface defining a fuel chamber; a cap portion defined at the top section of the sidewall; a plurality of burner ports defined along the sidewall of the body portion; and a gas conduit portion defining a gas inlet and a gas outlet, the gas outlet positioned adjacent the fuel chamber of the body portion; an igniter; and a gas supply conduit for supplying gas to the unitary gas burner.
 2. The gas burner assembly of claim 1, wherein the unitary gas burner is constructed using an additive process.
 3. The gas burner assembly of claim 1, wherein the unitary gas burner further comprises an interior support element projecting from the cap portion into the fuel chamber of the body portion.
 4. The gas burner assembly of claim 3, wherein the interior support element is conical in shape.
 5. The gas burner assembly of claim 1, wherein the plurality of ports are round in shape.
 6. The gas burner assembly of claim 1, wherein the interior surface of the body portion is curved.
 7. The gas burner assembly of claim 1, wherein the body portion is frustum-shaped.
 8. The gas burner assembly of claim 1, wherein the unitary gas burner further comprises an external support portion defined at the base section of the sidewall.
 9. The gas burner assembly of claim 1, wherein the cap has a circumference that is greater than the circumference of the sidewall at the top section of the sidewall.
 10. The gas burner assembly of claim 1, wherein the gas supply conduit is in fluid communication with the gas conduit portion of the unitary gas burner.
 11. A gas burner for a cooktop of an appliance, comprising: a body portion having a sidewall and extending between a base section and a top section, the body portion having an interior surface defining a fuel chamber; a cap portion defined at the top section of the sidewall; a plurality of burner ports defined along the sidewall of the body portion; and a gas conduit portion defining a gas inlet and a gas outlet, the gas outlet positioned adjacent the fuel chamber of the body portion, wherein the body portion, cap portion, and gas conduit portion are segments of a single, continuous piece of a material forming the gas burner.
 12. The gas burner of claim 11, wherein the gas burner is constructed using an additive process.
 13. The gas burner of claim 11, further comprising an interior support element projecting from the cap portion into the fuel chamber of the body portion.
 14. The gas burner of claim 13, wherein the interior support element is conical in shape.
 15. The gas burner of claim 11, wherein the plurality of ports are round in shape.
 16. The gas burner of claim 11, wherein the interior surface of the body portion is curved.
 17. The gas burner of claim 11, wherein the body portion is frustum-shaped.
 18. The gas burner of claim 11, further comprising an external support portion defined at the base section of the sidewall.
 19. The gas burner of claim 11, wherein the cap has a circumference that is greater than the circumference of the sidewall at the top section of the sidewall. 